Recent trends shape the future of DCS

Several trends have already impacted the distributed control
system (DCS) market and are likely to continue over the next
few years. These include both product- and technology-related trends and
general industry trends.

More intelligent I/O

The DCS input/output (I/O) subsystem is responsible for
inputting hundreds or often thousands of different process
measurements and other inputs into the system, and outputting
control signals to a large number of valves, actuators, motors
and other plant final-control elements. I/O represents one of
the most significant parts of the DCS. Traditionally, I/O is a
significant cost element. However, DCS suppliers are working to
reduce both the cost and complexity of their I/O systems by
incorporating more intelligence and programmability into the
devices.

Shift in I/O type

Fifteen years ago, the traditional process analog input came
from a sensor producing a 4-mA to 20-mA analog signal, and the
typical analog output was a 4-mA to 20-mA signal. Discrete
signals involved various combinations of voltages and currents.
Each signal type had a dedicated type of circuit board for the
individual signals.

Today, in a greenfield plant, most of the I/O supplied is on
some type of bus network. Brownfield plants are also installing
more bus I/O. However, with the large installed base of
tra-ditional 4-mA to 20-mA I/O, the transition is very slow.
Major expansions or revamps in brownfield
plants consider bus I/O when the sensors and final control
elements are also part of the project. There is also a growing
trend to adding more wireless I/O and associated field devices,
particularly for process and equipment monitoring
applications.

Need for network consulting services

As the lines between automation and IT are blurring with
increasing usage of commercial off-the-shelf (COTS) technology, the network
infrastructure of the DCS and the network architecture for
plant information are becoming increasingly more intertwined.
End users now often rely on the expertise of suppliers for
consulting to set up these networks in a safe and secure
manner.

Virtualization

DCS suppliers started incorporated server virtualization a
few years ago. Common uses of this technology include
engineering development and simulation for training.
Virtualization is not appropriate for all parts of the DCS.
Sometimes, the dedicated hardware will perform a given task
better than a virtual server. A good example is the real-time
process controller in a DCS, where speed, determinism and high
reliability are major design
considerations for the operation and safety of the plant.
Conversely, a virtual server performing many applications on
one box can be a good choice for offline applications such as
control configuration, simulation and training.

Cyber security

With more open and interoperable, largely COTS-based
automation systems, cyber security is becoming more important
as end users struggle with potential risks, both internal and
external to the DCS. Most suppliers now address this threat
with active programs, either inhouse or through partnerships.
As part of a defense-in-depth cyber-security
strategy, network fire walls and strategically placed switches
are required to help prevent the propagation of external
viruses and intrusions. Internal threats from disgruntled
employees or other internal access points must be addressed
with such things as USB locks and software to monitor internal
automation system network activity. Furthermore, network maintenance practices that are
common in the IT worldsuch as automatic software updates,
anti-virus updates and bug fixesmust be modified for the
mission-critical, 24/7 industrial environments in which DCSs typically
operate.

Mobility

Just as people today find it hard to live without their
smartphones in their daily lives, increasingly, process
operators and production supervisors are relying on the ability
to access data anywhere, anytime to do their job
functions. DCS suppliers address this trend by supplying tablet
technology for roving operators and
smartphones for alerts and condition monitoring. This trend
toward increasing mobility will grow in importance in the
future.

Cloud computing

There has been much talk in the industry about developments
underway to move selected DCS applications to the
cloud, a reference to moving applications to remote,
Internet (public) or intranet (private) servers. However, the
control-automation industry is very conservative by nature,
and, presently, this trend is just talk. ARC believes that,
ultimately, selected DCS applications will migrate to private
and, in some cases, even public clouds. For now,
end users are wary. HP

The author

Barry
Young has over 25 years of professional
experience in the process control and industrial
automation industry. Prior to joining ARC, he served as
a project manager for New
England Controls, where he helped design and implement
automation solutions for a variety of high-profile
clients in the life sciences, utility, pulp and paper
and other industries. Prior to New England Controls, he
handled a variety of responsibilities within the global
Invensys/Foxboro Company organization. Mr. Young has a
BS degree in management engineering from Worcester
Polytechnic Institute, and has completed MBA courses at
Bryant University. He is a member of the Project Management
Institute.

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